Support panel for removable brackets and the like

ABSTRACT

Support panels and modular assemblies thereof, the panels adapted for supporting removable load bearing members such as brackets. The panels comprise hollow bodies defining channels for receiving and supporting load bearing members. The hollow bodies further include support ribs extending between front and back walls of the panels to transfer forces exerted on flange portions of the channels by the load bearing members to the back walls and/or to other structural portions of the panels, the support ribs being offset from the perpendicular relative to the front and back walls of the panels. Pluralities of the panels may be joined by mating edges, which can define further channels for receiving and supporting load-bearing members, to form modular wall assemblies without the need for mounting overtop existing surfaces as said panels can be mounted directly on structural supports (e.g. stud walls).

FIELD OF THE INVENTION

The present invention relates generally to a support panel and moreparticularly to a support panel for supporting brackets and the like.

BACKGROUND OF THE INVENTION

Support panels are commonly used in office, commercial and otherenvironments in order to position various items, goods and productswithin easy reach and/or sight of people. For example, specially-adaptedsupport panels are often used as part of trade shows to display newproducts, in retail stores to display goods for sale, and in garages,workshops and other places where storage is required, to organize andmake easily available various tools.

Support panels define channels adapted for the mounting of varioussupport members (for example, shelves, racks, hangers and the like).Typically, such support members are provided with brackets which engagethe channels in order to securely hold the support members in place onthe support panel. Hence, the mounting of shelves etc. is performed inan easy and efficient manner, without the use of screws or other typesof fasteners. Support panels assembled from such walls are sometimesreferred to as slat walls.

A problem with existing support panels is that the panel structure isnot adapted to fully support the load that can be placed upon the panelby the brackets. If the load placed on a bracket exceeds the structuralstrength of a structure defining the channel, the structure is likely tofail, not only dropping the load, but also damaging the channelrendering that channel unusable. Thus, it is desirable to have supportpanels with channel structures that optimize the load carrying abilityof channels for both value and safety purposes.

SUMMARY OF THE INVENTION

The invention provides improved systems and methods for secure mountingof brackets and other load-bearing members on support panels. Inpreferred embodiments, the invention provides structures adapted for theremovable mounting of such structures.

In one aspect the invention provides support panels adapted forsupporting removable load bearing members such as brackets. Panelsaccording to such aspect can comprise hollow bodies having front and aback walls separated by voids, and one or more channels defined by thehollow bodies for receiving load bearing members. The channels caninclude openings defined in said front wall, and base and flangeportions defined by the hollow bodies for engaging the load bearingmembers. Such panels further comprise one or more support ribs extendingbetween the front and back walls to transfer forces exerted on theflange portions by the load bearing members to the back walls and/or toother structural portions of the panels.

It has been found that superior load-bearing qualities can be achievedby providing the support ribs at angles offset from the perpendicularwith respect to the front and back walls of the panels.

In other aspects, the invention provides modular wall assembliescomprising pluralities of such panels, wherein the panels are joined bymating edges which can define further channels for receiving andsupporting load-bearing members without any compromise in strength.

The invention also provides for flat rear panel surfaces which allowmounting on stud walls without the need for backing (such as drywall),where joined panels act as an adequate sealing means for a wallespecially at the corners where a void would be present.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by example, and with reference tothe accompanying drawings, in which:

FIG. 1 is an isometric view of a modular support panel in accordancewith an embodiment of the invention;

FIG. 2 is a cross section of the modular support panel of FIG. 1 viewedalong lines 2-2;

FIG. 3 is an enlarged partial view of the cross section of panel of FIG.2 as viewed in circle portion 3.

FIG. 4 is an enlarged, partial view of a modular support panel havingtwo support ribs in accordance with another embodiment of the invention;

FIG. 5 is an enlarged, partial view of a modular support panel havingtwo support ribs in accordance with yet another embodiment of theinvention;

FIG. 6 is an enlarged, partial view of a modular support panel having aT-shaped channel in accordance with another embodiment of the invention;

FIG. 7 is a portion of a wall formed from multiple modular supportpanels 30 of FIG. 1 in accordance with another embodiment of theinvention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an embodiment of a modular support panel isindicated generally at 30. As will be described further below, one ormore modular support panels 30 can be used in combination with eachother or with other suitable devices or materials to form a supportpanel wall or a portion thereof. Moreover, as will also be described ingreater detail below, modular panels 30 include channels 58 forreceiving and securely supporting load-bearing members such as brackets.

Referring to FIG. 2, each modular panel 30 has a front wall 34 and aback wall 38 that are substantially parallel to each other and separatedby distance D. Front wall 34 and back wall 38 are spanned by first edge42 and second edge 46 to form one or more hollow bodies 72. Front wall34 and back wall 38 are also spanned by one or more separation ribs 50defining one or more voids 54 within hollow body(ies) 72. In theembodiment shown in FIG. 2, modular panel 30 includes three separationribs 50, one for each of hollow bodies 72. Each separation rib 50 isconnected to its respective front wall 34 and back wall 38 in asubstantially perpendicular configuration. Moreover, each separation rib50 runs substantially parallel with ends 42 and 46. In otherembodiments, the configuration of ribs 50 can vary based on a variety ofcriteria such as costs, desired panel strength and other criteria aswould be understood by persons skilled in the relevant arts.

In a preferred embodiment, panel 30 is integrally formed from PVCthrough an extrusion process. In other embodiments, panel 30 may beconstructed from other plastics or materials, and formed throughdifferent processes, as understood by those with skill in the relevantarts. In yet other embodiments, one or more elements of panel 30 may beformed separately, and attached to panel 30 through additionalprocesses.

As will be apparent to those skilled in the relevant arts, the use ofhollow panels offers a number of advantages including, for example,reduced structural weight, and potential for improved insulation and/orfire retardation by, for example, filling voids 54 with insulating orfire retarding foams or other materials. Materials used to fill voids 54can be chosen based on numerous criteria such as desired panel strength,rigidity, fire retardation concerns, thermal and or audio insulation,cost and weight.

Modular support panel 30 defines, by itself and/or in cooperation withone or more other support panels 30, one or more channels 58 forreceiving brackets or other removable load-bearing members. As shown inFIG. 3, channels 58 include respective openings 62 for receiving theload-bearing members, as well as respective base portions 66 andretaining flange 78 for supporting the load-bearing members. FIG. 3shows an embodiment of a channel 58 defined by an integral channel wallhaving a base portion 66 and a side portion 70. In the embodiment shown,side portion 70 extends from base portion 66 and curves up to front wall34. A side portion 74 connected in a substantially perpendicular mannerto front wall 34 and base portion 66 defines the other side of channel58. In this embodiment, base portion 66 is reinforced with separationrib 67, one of which comprises a section of side portion 74.

Referring still to FIG. 3, flange 78 can be formed in variousconfigurations, using different structures. For example, as shown inFIG. 3, flange 78 extends a distance D1 from side portion 74 to form anintegral u-shaped structure comprising inner surface 88 and outersurface 82. Outer surface 82 is connected to front wall 34 and innersurface 82 is connected to side portion 74. In this embodiment, sideportion 74 comprises spanning rib 68, which spans the distance betweeninner surface 88 and outer surface 82 of flange 78. Preferably, flange78 is configured to define at least a portion of receiving channel 58and to support loads applied to an inner surface of the flange, theloads comprising at least a vector component normal to the front wall34. In the embodiment shown in FIG. 3, flange 78 is substantiallyparallel with front wall 34, the outer surface 82 of flange 78 being insubstantial alignment with the outer surface of front wall 34. In otherembodiments, flange 78 can take other shapes such as L-shapedprotrusions or other configurations as would be understood by thoseskilled in the relevant arts. Flange 78 can be constructed fromsubstantially the same material as the majority of panel 30, or can beconstructed of a different suitable material. In yet other embodiments,flange 78 can be aligned with front wall 34 in a non-parallel fashion,and/or connected at other locations on side portion 74, such that frontportion 82 is not aligned with front wall 34.

As will be understood by those of skill in the relevant arts, a suitablesupport member, such as a shelf (not shown) with a bracket thatcomplements the shape of channel 58, can be used with support panels 30.In use, the bracket is inserted into channel 58 such that the shelf isheld substantially perpendicular to support panels 30. In order tosupport the shelf in this configuration, and any extra weight that theshelf itself must support, the bracket exerts a force, or a load, atleast partially on inner surface 88 of flange 78 and at least partiallyon base portion 66.

Panels 30, in accordance with the invention, can comprise additionalstructural members for providing support to load-bearing portions ofpanel 30. For example, in some embodiments of the invention, panels 30comprise one or more support ribs 86 located within void 54 fortransferring torsional, bending, and/or other loads applied to flange 38by, for example, a removable load-bearing support member. Support rib 86can be proximate to side portion 74, and extends between front wall 34and back wall 38. In general, support rib 86 supports the load-bearingcapabilities of flange 78 and may allow for greater loads to besupported by support panel 30.

Referring now to FIG. 4, support rib 86 is shown connected to front wall34 and back wall 38. Support rib 86 and back wall 38 define angle 110through their connection. Angle 110 is preferably less than about 90degrees such that support rib 86 is closer to side portion 74 at frontwall 34 than at back wall 38. As will be understood by those familiarwith such structures and the support of load-bearing members, the valueof angle 110 and the orientation of support rib 86 in relation to backwall 38 can be varied. For example, angle 110 can be in the range ofabout 20 to about 85 degrees, more preferably in the range of about 40to about 70 degrees, and even more preferably in the range of about 50to about 70 degrees. An angle 110 of about 65 degrees has been found toserve particularly satisfactorily.

Support rib 86 is preferably attached to front wall 34 at a distancefrom side portion 74 that is between zero to about 4 times D1 (thedistance that flange 78 extends from side portion 74, as describedabove). It is even more preferred that support rib 86 is attached tofront wall 34 at a distance from side portion 74 that is in the range ofbetween about 0.5 times to about 3.5 times D1, and even more preferredthat support rib 86 is attached to front wall 34 at a distance from sideportion 74 that is in the range of between about 1.5 times to about 3.0times D1, and even more preferred that support rib 86 is attached tofront wall 34 at a distance from side portion 74 that is in the range ofbetween about 2 times to about 2.7 times D1. In some embodiments,support rib 86 can be attached to front wall 34 at a position as closeto side portion 74 as the corner formed by side portion 74 and frontwall 34.

Front wall 34 and back wall 38 may be generally parallel to each otherand are separated by distance D2. A suitable distance D2, as well assuitable thicknesses of the walls and other components of the panel, canbe determined by a person skilled in the relevant arts, and willgenerally be dependent on the materials used to construct them, as wellas the desired loads that they are expected to bear, and variousmanufacturing practicalities.

In another embodiment of the present invention, a second support member86 is used, as shown in FIG. 4. Second support member 86 can be attachedto front wall 34 at a distance anywhere along void 54, but it ispreferred that it is attached to front wall 34 at a distance from sideportion 74 that is between zero to about 4 times D1. It is even morepreferred that support rib 86 is attached to front wall 34 at a distancefrom side portion 74 that is in the range of between about 0.5 times toabout 3.5 times D1, and even more preferred that support rib 86 isattached to front wall 34 at a distance from side portion 74 that is inthe range of between about 1.5 times to about 3.0 times D1, and evenmore preferred that support rib 86 is attached to front wall 34 at adistance from side portion 74 that is in the range of between about 2times to about 2.7 times D1.

It is not required that each support member 86 has the same angle 110.The angles will be determined by the particular load requirements. Forexample, an embodiment is shown in FIG. 5 where second support member 86has a smaller angle 110 than the first support member. In thisembodiment, second support member 86 is shown attached to front wall 34at the same distance from side portion 74 as the first support member.In other embodiments, second support member 86 can have a different able110 and be attached to front wall 34 at a different distance from sideportion 74.

In theory, there is no limit to the number of support ribs 86 that couldbe used; however, a skilled person could determine a practical number ofsupport ribs 86, and their relative location, useful to support adesired load.

Referring back to FIG. 2, multiple panels 30 can be joined, at theirrespective mating ends 42 and 46, to form a continuous modular wallassembly. Ends 42 and 46 can comprise male-female or other matingconfigurations such as that shown, which includes a female joint portion112 at end 42 and a male joint portion 114 at end 46. The embodimentshown in FIG. 2 further comprises flange portion 118 and wall structures119, 120, 121 at ends 42, 46, such that when an end 42 is joined orotherwise placed in a proximate configuration to an end 46 to form awall assembly, a channel 58 for receiving a load-bearing member can beformed by the respective ends 42, 46.

FIG. 5 shows a portion of a modular wall assembly, or modular supportpanel system, 200 in accordance with such an embodiment of theinvention. Panel system 200 is formed by joining two modular panels 30 aand 30 b. Modular panel 30 a and modular panel 30 b are similar tomodular panels 30, and like elements in modular panel 30 a and modularpanel 30 b bear reference numbers similar to those of like elements inmodular panels 30.

In the embodiment shown, a channel 122 is formed, or defined, where anend 42 meets an end 46. Accordingly, as shown in FIG. 5, the opening 62of channel 122 is defined by front wall(s) 34 and flange 118.Furthermore, portion 119 of end 42 between front wall 34 a and femalejoint 110 a forms one side portion of channel 122. Portion 121 of end 46between front wall 34 b and male joint 114 forms another other sideportion. A portion 120 of male joint 114 that remains outside femalejoint 110 forms a base portion for channel 122.

In the embodiment shown, a support rib 130 is located proximate to end46. As should be apparent to those skilled in the relevant arts, allvariations discussed above for support rib 86 are also applicable tosupport rib 130 and are within the scope of the invention.

Modular wall assembly 200 can be secured to an existing wall system, orsuitably supported by other means known in the art. For example, modularwall assembly 200 can be mounted directly on structural supports (e.g.stud walls). Alternatively, modular wall assembly 200 may comprisesuitable supporting means to enable it to be self supporting such thatminimal extra supporting means are required.

As shown, for example, in FIG. 2, it can be advantageous in someembodiments for panel 30 to include a plurality of channels 58. As willbe understood by those skilled in the relevant arts, the relativespacing and configuration of channels 58 can be selected to accommodatedesired loading configurations when load-bearing members are installed.

In another embodiment of the present invention, a panel 30 with opposingflanges 78 forming a “T” channel, as shown in FIG. 6, is provided. Inthis embodiment, an opening 300 is defined between opposing flanges 78.Opening 300 leads into channel 310, which is defined by side portions320 and base portion 330. Support members 86 are provided to supporteach flange 78 and may be mirror reflections of each other or different.The parameters for support members 86 are as already described. In thisembodiment, support member 86 can support only one flange 78 of the “T”channel or both.

While the invention has been described in some detail for purposes ofclarity and understanding, it will be appreciated by those skilled inthe relevant arts that various changes in form and detail can be madewithout departing from the true scope of the invention in the appendedclaims. The invention is therefore not to be limited to the exactcomponents or details of methodology or construction set forth above.

1. A support panel for supporting one or more removable load bearingmembers, said support panel comprising: a body having a front wall and aback wall; at least one channel defined in said body for receiving atleast one load bearing member, said channel having an opening defined insaid front wall, a base portion, and a flange portion for engaging saidload bearing member; and at least one support rib extending between saidfront wall and said back wall, each support rib extending at an angle ofbetween 30 and 85 degrees relative to the back wall.
 2. The supportpanel of claim 1, wherein each support rib extends at an angle ofbetween 40 to 70 degrees relative to the back wall.
 3. The support panelof claim 1, wherein said support rib extends at an angle of between 50to 60 degrees relative to the back wall.
 4. The support panel of claim1, wherein said support rib is connected to said front wall at alocation zero to four times the width of the flange.
 5. The supportpanel of claim 1, wherein said support rib is connected to said frontwall at a location in the range of between about 0.5 times to about 3.5times the width of the flange.
 6. The support panel of claim 1, whereinsaid support rib is connected to said front wall at a location in therange of between about 1.5 times to about 3.0 times the width of theflange.
 7. The support panel of claim 1, comprising at least one basereinforcement rib spanning said base portion and said back wall forreinforcing said base portion.
 8. The support panel of claim 1 whereinsaid flange is u-shaped.
 9. The support panel of claim 4, comprising aspanning member spanning two ends of the u-shape of said flange forstrengthening said flange.
 10. The support panel of claim 1, comprisingedges adapted for modular connection to mating edges of other panelstructures.
 11. The support panel of claim 10, wherein the edges adaptedfor modular connection are configured such that when mated with edges ofother panel structures the edges and mating edges form a channel forreceiving at least one load bearing member, said channel having anopening, a base portion and a flange portion defined by the edges andmating edges.
 12. The support panel of claim 1, comprising a pluralityof support ribs extending between said front wall and said back wall,each of said support rib extending at an angle of between 30 and 85degrees relative to the back wall.
 13. The support panel of claim 12,wherein at least one of said support ribs is connected to said frontwall at a location within approximately zero to four times the width ofthe flange.
 14. The support panel of claim 12, wherein at least two ofsaid support ribs define angles with the back wall that are notequivalent.
 15. The support panel of claim 1, comprising a plurality ofchannels defined in said body for receiving load bearing members, eachsaid channel having an opening defined in said front wall, a baseportion and a flange portion defined by said body for engaging at leastone load bearing member.
 16. A support panel for supporting one or moreremovable load bearing members, said support panel comprising: a bodyhaving a front wall and a back wall; at least one channel defined insaid body for receiving at least one load bearing member, said channelhaving an opening defined in said front wall, a base portion, and twoflange portions such that the channel forms a “T” shape; and at leastone support rib extending between said front wall and said back wall,each support rib extending at an angle of between 30 and 85 degreesrelative to the back wall.
 17. A modular support panel system forsupporting at least one removable load bearing member, said systemcomprising a plurality of support panels, each said support panelcomprising: a body having a front wall and a back wall; and first andsecond edges configured such that two adjacent panels can be linked byadjoining a first edge of one panel to a second edge of the second panelto form a wall structure; the first and second edges of adjacent panelsdefining, when joined, a channel for receiving said at least one loadbearing member, said channel having an opening defined by the frontwalls of the adjacent panels, a base portion, and a flange portion forengaging said load bearing member; at least one of the support panelsfurther comprising a support rib extending between its front wall andits back wall, said support rib extending at an angle of between 30 and85 degrees relative to the back wall.
 18. A support panel for supportinga removable load bearing member, said support panel comprising: a bodyhaving a front wall and a back wall; a channel defined in said body forreceiving said load bearing member, said channel having an openingdefined in said front wall, a side portion perpendicular to said frontwall and said back wall, and a flange defined by said body for engagingsaid load bearing member; and a support rib extending between said frontwall and said back wall to transfer force exerted on said flange by saidload bearing member toward said back wall, said support rib extending atan angle of between 10 and 50 degrees relative to the back wall.